06 aveo5 LSJ supercharged engine swap

[Suprasalas1]

I am converting the rear to a 5 lug, this will allow me to use the same rims as the front and convert it to rear disc brakes for better braking assist.

[Suprasalas1]

Finally got one side done, hands down this is no walk in the park. The rear hub where it bolts on to the frame have a different bolt pattern it took me all night to find a way to make it work.

[Daox]

Wow, that is some real work done there!

How did you remove the large circle of material from the rear sub frame? It looks like a hole saw?

[Suprasalas1]

For most part of it I used a hole saw 2" 3/8, but for some reason about 3/4 of the way it stop cutting. I think it was getting cough up with the inside drill bit plus it ended up smoke testing my Milwaukee drill so I pulled out my reciprocating air saw to finish it. I still have work to do on it but ill have to wait to finish the drivers rear side. I just ordered the parking brake cable from a cobalt so i can use the parking brake when needed to and see where the caliper is going to sit. But for now ill start on the passengers rear it should be simpler since i have an idea how to do it.

Wow, that is some real work done there!

How did you remove the large circle of material from the rear sub frame? It looks like a hole saw?

[MetroMPG]

Can't press "THANKS" enough for documenting this so well here!

Any more updates?

[JJJoseph]

Can you tell us what is an "lsj supercharged"?

[northguest47]

Best thread eva 'nuff said

[Suprasalas1]

Can you tell us what is an "lsj supercharged"?

Lsj is a engine off an 05 to 07 cobalt 2.0 supercharged

[Suprasalas1]

Can't press "THANKS" enough for documenting this so well here!

Any more updates?

Thank you for following my progress, but I have ran into a problem with the rear brakes. The rear caliper spring for the hand brake hits the aveo rear coil spring which I had to remove for the caliper to fit. I have two options either removal the coil spring and install a coilover system off a 80's vw golf or fabricate the whole rear suspension. I am leaning more and more to just fabricate a tubular rear suspension to solve these problems.

[Suprasalas1]

So I finally diced in on how to set up the rear end suspension, now understand if you are swapping your aveo you don't have to make the rear 5 lug conversion you can actually buy rims that are 5 lug for the front and 4 lug for the rear with the same design. I just went this route because I wanted something different, I will be redesigning the rear end using 1 1/4 thick wall tubing. I will be also be making the front lower control arms from 1in tubing.